Effect of Heat Treatment on the Microstructure and Mechanical Properties of LB-PBF AlSi10Mg and Scalmalloy

Baig, Shaharyar; Ghiaasiaan, S. Reza; Shamsaei, Nima

doi:10.1007/978-3-030-65396-5_18

Cited by 4 publications

(2 citation statements)

References 21 publications

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“…The powder was sieved to a particle size of 105 µm for the powder-fed DED process. Scalmalloy is a highstrength lightweight alloy widely used in the AM process for aluminum deposition [60][61][62]. The material also exhibits excellent corrosion resistance.…”

Section: Methodsmentioning

confidence: 99%

A Novel Laser-Aided Machining and Polishing Process for Additive Manufacturing Materials with Multiple Endmill Emulating Scan Patterns

et al. 2021

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In additive manufacturing (AM), the surface roughness of the deposited parts remains significantly higher than the admissible range for most applications. Additionally, the surface topography of AM parts exhibits waviness profiles between tracks and layers. Therefore, post-processing is indispensable to improve surface quality. Laser-aided machining and polishing can be effective surface improvement processes that can be used due to their availability as the primary energy sources in many metal AM processes. While the initial roughness and waviness of the surface of most AM parts are very high, to achieve dimensional accuracy and minimize roughness, a high input energy density is required during machining and polishing processes although such high energy density may induce process defects and escalate the phenomenon of wavelength asperities. In this paper, we propose a systematic approach to eliminate waviness and reduce surface roughness with the combination of laser-aided machining, macro-polishing, and micro-polishing processes. While machining reduces the initial waviness, low energy density during polishing can minimize this further. The average roughness (Ra=1.11μm) achieved in this study with optimized process parameters for both machining and polishing demonstrates a greater than 97% reduction in roughness when compared to the as-built part.

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Section: Methodsmentioning

confidence: 99%

A Novel Laser-Aided Machining and Polishing Process for Additive Manufacturing Materials with Multiple Endmill Emulating Scan Patterns

et al. 2021

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“…The rest of the solutionized specimens were artificially aged, that is, T7 for 16 h at 165 C. The aging times were selected based on a preliminary microstructural/hardness evolution study that determined the peak aged (T6) and over aged (T7) conditions of the material. 23 For comparison, the properties obtained in this study are presented alongside the ones from reference 12 in the experimental results section. The HT in Muhammad et al 12 consisted of stress relieving at 300 C for 2 h and allowing the specimens to NA before mechanical testing.…”

Section: Ht Proceduresmentioning

confidence: 99%

Tensile and fatigue behaviors of additively manufactured AlSi10Mg: Effect of solutionizing and aging heat treatments

Baig

Ghiaasiaan

Shao

et al. 2023

Fatigue Fract Eng Mat Struct

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The effects of various heat treatments on the microstructure and mechanical properties of laser beam powder bed fused AlSi10Mg were investigated. Specimens were solutionized at three different temperatures of 425 C, 475 C, and 525 C followed by natural aging (T4) prior to microstructural and mechanical characterization. In addition, the effect of aging was studied by artificially aging (i.e., T7) some of the solutionized specimens at 165 C. Solutionizing at all temperatures was observed to fully dissolve the additive manufacturing (AM) induced dendritic microstructure, leaving bulky Si and needle-shaped β-AlFeSi precipitates in the grain interiors and boundaries. Tensile results revealed that T4 specimens exhibited more ductility, while T7 specimens showed substantially higher strengths with slightly reduced ductility. Interestingly, no significant effect of heat treatment on strain-life fatigue behavior was observed. Fractography found the Si particles to be responsible for tensile fracture, while AM volumetric defects were the main initiators of fatigue cracks.aluminum, fatigue, laser beam powder bed fusion (LB-PBF/L-PBF), microstructure, tensile Highlights• Effect of heat treatments on tensile and fatigue behavior of L-PBF AlSi10Mg studied.• T7 treatment led to higher tensile strengths than T4, but similar fatigue lives.• Tensile failure initiated from Si-particle fracture or debonding from matrix.• Fatigue life was affected by the size of crack initiators, that is, volumetric defects. | INTRODUCTIONAluminum alloys are commonly used in various industries because of their superior strength/stiffness to weight ratio compared to other alloys. 1,2 Among various Al alloys, AlSi10Mg as a cast alloy 2 has historically been used to fabricate complex/thin-walled geometries. Recently, processing AlSi10Mg through additive manufacturing (AM) has shown to be very promising as intricate, lightweight parts can be manufactured without

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Parameter study of an Al–Cr–Mo–Sc–Zr alloy processed by laser powder bed fusion reaching high build rates

Agricola,

Bierwisch,

Palm

et al. 2024

Prog Addit Manuf

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Market availability of aluminum alloys for laser powder bed fusion (L-PBF) is still highly limited in comparison to conventional manufacturing processes. The demand for high-strength but inexpensive alloys specifically designed for L-PBF is high. This demand has led to research on a variety of adapted conventional alloys which are still limited to utilize the full potential of L-PBF. Scalmalloy® (Al–Mg–Sc–Zr) satisfies the demand for high-strength L-PBF-alloys but needs a high energy input and has troubles with evaporation of Mg. Scancromal® (Al–Cr–Sc–Zr) is a novel alloying system for L-PBF and was first introduced in 2019 with the possibility of higher build rates and comparable strengths to Scalmalloy®. In this paper, a more economic low Sc-containing version of Scancromal® is presented. A parameter study was performed for $${100}\,\upmu \hbox {m}$$ 100 μ m layer thickness reaching high build rates of about $${47}\,\hbox {cm}^{3}\,\hbox {h}^{-1}$$ 47 cm 3 h - 1 . Hardness tests for different parameters were carried out and showed a stable process window with a hardness comparable to AlSi10Mg. Additionally, two-dimensional multilayer process simulations showed a potential for increasing the layer thickness to $${150}\,\upmu \hbox {m}$$ 150 μ m and therefore a significant increase in build rate of up to $${70}\,\hbox {cm}^{3}\,\hbox {h}^{-1}$$ 70 cm 3 h - 1 highlighting the high productivity potential of Al–Cr alloys for L-PBF.

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Effect of Heat Treatment on the Microstructure and Mechanical Properties of LB-PBF AlSi10Mg and Scalmalloy

Cited by 4 publications

References 21 publications

A Novel Laser-Aided Machining and Polishing Process for Additive Manufacturing Materials with Multiple Endmill Emulating Scan Patterns

A Novel Laser-Aided Machining and Polishing Process for Additive Manufacturing Materials with Multiple Endmill Emulating Scan Patterns

Tensile and fatigue behaviors of additively manufactured AlSi10Mg: Effect of solutionizing and aging heat treatments

Parameter study of an Al–Cr–Mo–Sc–Zr alloy processed by laser powder bed fusion reaching high build rates

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